INSTRUCTION MANUAL KC/5-S Rotating Consistency Transmitter

Transcription

INSTRUCTION MANUAL
KC/5-S
Rotating Consistency Transmitter
W41040300 V3.01
September 2006
This manual W41040300 V2.34 is applicable for KC/5 firmware V1.10 or higher (KC/5 transmitters delivered since
August 2005 or upgraded)
Manual V2.3. New Measurement Chamber and installation, Appendix 4 & 5 modified, print new manual.
V2.31, Zero torque setup instructions updated, print pages 17 and 31-32.
V2.32, Default calibration parameters corrected. Print page 29.
V2.33, Specifications updated
Software changes :
V1.02ÆV1.03: Start-up procedure added to Calibration menu (In-air torque)
V1.03ÆV1.04: Reset of Output Filter after the process stop
Possible to edit Friction alarm limit in Factory Settings
Added Power supply min. and max. temperature to Data Log
Decreased Auto reverse timing, now minimum times 5seconds after each 1 minutes
V1.04ÆV1.05: Corrected Year in Data Log, V1.04 displayed Year sometimes wrong
V1.05ÆV1.10: Auto-zero function
V1.10 -> V1.11: Spike removal software using std deviation added
Manual V3.0. KC/5-S sensor, Measurement Chamber V1.1, Insertion Housing 67. ISO-torq adapter removed, fixed
(flange) installation removed.
KC/5 Safety Notice!
PLEASE FOLLOW THESE INSTRUCTIONS CAREFULLY TO AVOID POSSIBLE
INJURY!
Kajaani Process Measurements’ KC/5 standard retractable version is designed for applications where line pressure is
less than 10/16 bar (150/232 pounds per square inch (psi). A special, non-retractable model is available for use in
applications with higher line pressures.
The KC/5 is shipped in completed sub-assemblies. All safety related components are checked and verified to work
correctly, before the product is shipped from our factory. The Customer is responsible for proper, safe installation by
following the procedures outlined in the KC5 “Instruction Manual” included with each KC/5 shipment.
Special care must be taken to ensure that the “Locking Ring” part #H41040131V1.0, part of the installation hardware,
is properly tightened at all times according to the “Instruction Manual”.
If the “Jack Assembly” part number A41040175V1.0, has been damaged and neither the “Seal Sleeve Assembly” nor
the “Locking Ring” is secured according to the “Instruction Manual”, Section 3.5, the KC/5 Sensor may be propelled
out of the line by the line pressure causing possible injury.
The KC/5 Sensor must be securely locked into place with the “Locking Ring” after every instance where the sensor is
removed and re-inserted into the process, or after the “Seal Sleeve Assembly” is disassembled and re-assembled. All
persons who work on the KC/5 must follow all instructions in the “Instruction Manual”, Section 3.5, and in this Safety
Notice, to eliminate any chance for injury when working on the KC/5.
The “Locking Ring” and the “Jack Assembly” are critically important to the safe use of the KC/5 transmitter. Each
must be properly attached, and securely tightened in place, while the sensor is inserted into the process line. When the
Gate Valve is opened, the Sensor may be withdrawn from the line by slightly loosening the “Locking Ring”. The “Jack”
then withdraws the Sensor from the process so the Gate valve may be closed. Only after the closed Gate Valve has
isolated the line pressure from the withdrawn Sensor, is it safe to loosen the “Jack Assembly” and remove the
“Locking Ring”.
It is critically important to make certain that both the “Locking Ring” and the “Jack Assembly” are secured according to
the procedures outlined in the “Instruction Manual”, Section 3.5, during initial installation and before each attempt to re
- insert the Sensor into the process line.
Note! Make sure all Bolts and Nuts are tightened properly before opening the gate valve.
September 2006
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Table of contents
KC/5 Safety Notice! .............................................2
PLEASE FOLLOW THESE INSTRUCTIONS
CAREFULLY TO AVOID POSSIBLE
INJURY! ....................................................2
1.1 Introduction ..................................................4
1.2 Contact information......................................4
1.3 Unpacking and inspection............................5
1.4 KC/5 system description ..............................6
1.5 Measuring principle......................................6
1.6 Sensing element ..........................................8
2.1 General notes ..............................................9
2.2 Selecting the optimum measuring site.........9
2.3 Dimensions and clearance requirements
of the sensor ..............................................11
3.1 Process connections..................................12
3.2 Installing the Measurement Chamber........12
3.3 Installation to a BTG MEK process
connection..................................................14
3.4 Installing the gate valve assembly .............15
3.5 Insertion of the sensor ...............................17
Preparing for insertion .............................17
Inserting the sensor.................................17
Safety Check after each insertion to the
process line .............................................18
3.6 Flange Installation PN25............................20
3.7 Seal water connection ...............................20
3.8.1. Low pressure water flushing....................20
3.8.2. Self contained seal water system............21
3.8 Insertion depth adjustment ........................22
3.9 Installation of the display unit.....................22
4.1 Display unit connections ............................23
4.2 Sensor unit connections ............................24
5.1 Operation of the KC/5 – operator
interface .....................................................24
5.2 Menu structure ...........................................26
5.3 Set-up ........................................................30
6.1 Calibration menu........................................32
6.2 Torque Offset (Zeroing of the torque
measurement system) ...............................32
6.3 Single-point calibration ..............................33
6.4 Zero adjustment .........................................33
6.5 Sampling procedure...................................33
6.6 Changing calibration parameters...............34
6.6.1. Manual adjustment ..................................34
6.6.2. Transmitter calculated parameter
change.....................................................34
7.1 Regular maintenance of the KC/5..............35
Seal water reservoir (optional, when mill seal
water is not suitable) ...............................35
7.2 Maintenance menu ....................................35
7.3 Motor controls ............................................37
7.4 Troubleshooting .........................................38
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7.5
7.6
7.7
7.8
Removing the KC/5 sensor ....................... 40
On-line Zero check .................................... 41
On-line sensitivity check............................ 41
Checking the functionality of the KC/5 by
removing the sensor from the process...... 42
7.9 Torque sensitivity calibration..................... 42
7.10 Cleaning the sensing element................... 42
7.10.1. Cleaning debris wrapped around the
sensing element using “Auto Reverse.... 42
7.10.2. Cleaning the sensing element manually43
7.11 Replacing elastic shield, rod seal and
needle roller bearing ................................. 43
7.11.1. Removing elastic shield ........................ 44
7.11.2. Removing rod seal and needle roller
bearing.................................................... 44
7.11.3. Installing elastic shield, rod seal and
needle roller bearing ............................... 45
7.12 Replacement of the mechanical seals ...... 46
7.12.1. Removing front mechanical seal........... 47
7.12.2. Removing rear mechanical seal ........... 48
7.12.3. Installation of front and rear
mechanical seals .................................... 48
7.13 Electronics................................................. 50
7.14 Replacing Sensor Board ........................... 52
7.15 Replacing Optics Board ............................ 53
7.16 Replacing Power Supply Unit.................... 53
7.17 Replacing Connection Board .................... 54
7.18 Replacing LC Display Board ..................... 55
Appendix 3.1.: Standard Meas. Chamber,
PN10 Gate Valve .................................... 58
PN16 Gate Valve .................................... 59
PN25 ...................................................... 61
Appendix 3.4.: BTG Adapter, PN10 Gate Valve62
Appendix 3.5.: BTG Adapter, PN16 Gate Valve64
Appendix 3.6.: Sensor Front Assembly,
PN16SS .................................................. 63
Appendix 3.7.: Moment shaft and motor
assembly................................................. 64
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1. Introduction
1.1 Introduction
The robust design meets the demands of the harsh pulp and paper mill environment and provides the user
with an accurate reading of pulp consistency for use in many control applications.
In order to get the best results from the KC/5 transmitter, please read this manual carefully. The information
provided in this manual provides clear and useful information to better understand installation requirements,
set-up procedures, and the effective operation of the KC/5 rotating consistency transmitter in your
application. By reading and understanding this information, your facility will be best able to optimize the
performance of KC/5 transmitter to suit your specific needs and requirements.
1.2 Contact information
Europe, Asia and South America:
Kajaani Process Measurements Ltd.
PO BOX 94
FI – 87101 Kajaani, Finland
Tel:
+358 8 633 1961
Fax:
+358 8 612 0683
E-mail: kpm@prokajaani.com
North America:
Kajaani Process Measurements Inc.
636 U.S. Route 1, Box # 4
Scarborough, ME 04074, U.S.A
Tel:
207 883 1095
1 800 consist (266 7478)
Fax:
+1 207 883 1104
E-mail:
kpmusa@prokajaani.com
Japan:
Kajaani Process Measurements Ltd.,
Japan Branch Office
K. Doi
4-444-5 Nishimiyashita
Ageo-shi, Saitama-Ken
362-0043 Japan
Tel:
+81 487 776 7695
Fax:
+81 487 776 8469
Mobile: +81 90 7633 8960
E-mail: k.doi@prokajaani.com
Please find your local supplier on www.prokajaani.com
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1.3 Unpacking and inspection
Note: When unpacking the KC/5, check for shipping damage and verify the contents against the
packing list. Immediately report any damage or missing items to ensure prompt repair and/or
replacement as needed.
The standard system contains following items in 4 separate boxes (See figure 1-1):
Sensor A41040157V1.0
Interconnect Cable A41040095V1.0
Gate Valve Ass'y, PN 10 A41040224V1.0
Or Gate Valve Ass'y, BTG Adapter A41040159V1.0
Insertion Jack
A41040175V1.0
Display Unit
A410400179V1.0
Instruction Manual
W41040300V1.0
Figure 1-1. KC/5 standard system components
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1.4 KC/5 system description
The KC/5 consists of the Sensor Unit with the Mounting Assembly and the Display Unit (See figure 1-2).
KPM offers five (5) installation options:
1. KPM Standard Measurement Chamber with Gate Valve and installation jack.
2. BTG MEK adapter with Gate Valve and Installation Jack.
3. Flange installation with KPM Measurement Chamber without Gate valve and Installation Jack.
4. Mounting bracket for mounting on open vessel (i.e. stuff box or saveall drop chest).
5. Flanged Adaptor for ISO-torq installation without KPM measurement Chamber or new Gate Valve, and
new Installation Jack
The Measurement Chamber is welded to the process pipeline (min. diameter 150mm, 6”). The DN80 (3”)
gate valve is mounted to the Measurement Chamber. Sensor probe is inserted into the process by the
heavy duty insertion jack which is mounted to the gate valve assembly.
The display unit is connected to the sensor unit by a 10 m (33 ft) long, shielded 10-conductor cable
(maximum length available is 30 m (100 ft)). The cable includes a connector that can be quickly coupled to
the sensor unit. Display unit is powered by 85-264 VAC/47-63 Hz and supplies 12/48 VDC to the sensor. All
external electrical connections are made in the display unit (4 – 20 mA analog output, binary inputs). The
sensor motor can be interlocked with “stock pump running” information (pump) via binary input in display
unit.
Figure 1-2. The KC/5 sensor unit with the display unit.
1.5 Measuring principle
The KC/5 sensor unit rotates the sensing element (see Figure. 1-3) in the pulp slurry. The slurry resists the
movement. To overcome this resistance, a torque force is created. The higher the consistency, the greater
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is the force. The KC/5 measures the torque and converts this torque measurement into a consistency
measurement value.
KC/5 uses a “direct drive” servomotor. The “stator” is mounted in the body of the sensor unit, and the “rotor”
integrated into drive shaft assembly. There is no drive belt or gearbox in the KC/5 design.
The motor rotates two optical discs. One, the drive disc, is attached to the drive shaft. The other, the
moment disc is coupled to the drive disc with coil springs. The moment disc is mounted to the moment shaft
– the sensing element is located in the opposite end of moment shaft.
When the drive shaft rotates, the springs force the moment disc to follow. The force-resisting movement
varies, depending upon the consistency of the slurry within which the sensing element rotates. With higher
resisting force, the springs stretch more and the moment disc lags farther behind the drive disc. At less
resistance, discs follow closer to each other. The discs rotate at the same speed. As Cs increases,
however, the “phase shift” between the two discs increases in direct proportion to the degree of torque
applied.
Figure 1-3. Measuring principle
A high-resolution optical sensor detects the Phase Shift of the windows as consistency changes.
Measurement electronics convert the optical signal into a calibrated torque value. The KC/5 system
measures torque from zero - no torque applied to the sensor element - to a maximum 2000 mNm(170)
ounces per inch. The accuracy is factory calibrated using torque standards. Each KC/5, therefore, has the
same Cs sensitivity, making all sensors interchangeable without re-calibration.
Torque is generated by shear force that changes when a rotating sensing element cuts through a moving
fiber network (see Figure 1-4). As the curve shows, the torque generated by a rotating sensing element is
not linear with consistency, but rather, increases more steeply at higher consistencies.
The measurement algorithm in the KC/5 linearizes the relationship between consistency and the torque
value. The KC/5 then calculates the output consistency as follows:
C% = S * M + Z
Where:
C
S
M
Z
=
=
=
=
Consistency
Slope
Measurement signal (linearized torque reading)
Zero offset
Slope (S) and offset (Z) are grade specific. KC/5 comes with seven pre-calibrated consistency curves that fit
most applications in the mill. One additional “user defined” grade is for special applications.
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100
Torque [mNm]
Torque curvature gets steeper
with increasing consistency
Linearized measurement
signal
Reading in water at 0%
Reading "in air"
0
Consistency [%]
0
Figure 1-4. Relationship between torque and consistency.
1.6 Sensing element
KC/5 transmitter is provided with the paddle type sensing element as standard (See figure 1-5).
Sensitivity of shear force measurement is directly proportional to the amount of “cutting surface” of a sensor
element.
The paddle-style sensing element has very large cutting surface area providing excellent sensitivity over full
measurement range.
2 Paddle sensing element is for general purpose and provides similar signal as paddle sensing element.
4 Paddle sensing element is used to give additional sensitivity on very low consistencies.
Plane sensing element is stream-lined and is less likely to pick up stringy debris as are typically
encountered in unscreened recycle and “broke-line” applications.
Half-Plane is for medium consistency (>8% Cs) applications.
Paddle
2 Paddle
4 Paddle
Plane
Half-Plane
Figure 1-5. Sensing elements
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2. Location and installation requirements
2.1 General notes
The KPM transmitters are designed and manufactured to provide accurate and reliable measurements over
a long period of time. Correct installation will ensure maximum performance and minimum cost of
ownership.
Avoid installing the transmitter around heavy vibration sources (e.g. cavitating or unbalanced pumps).The
KC/5 has two seal water options, Mill seal water or integrated seal water reservoir. Mill seal water is
recommended in applications with fillers and with recycled pulp.
Install a reliable sampling valve close to the transmitter. Poor sampling leads to inaccurate calibration and
underperformance of the measurement. KPM KS- samplers provide consistent and reliable solution for any
sampling application.
2.2 Selecting the optimum measuring site
Selecting the ideal location and installing the KC/5 properly are keys to successful measurement. Look for
the site that:
1: Optimizes the performance of the instrument.
2: Provides clear access for maintenance.
KC/5 rotating type transmitter is installed in the Measurement Chamber. The insertion depth of the sensing
element is adjustable allowing to locate the sensing element to best measuring position also in difficult flow
conditions. See fig. 3.10.
Minimum straight pipe sections for transmitter:
Low consistency 1.5 – 8%:
Calming length Lbefore = 3 * D or 1 m (3 feet) whichever is longer
Calming length Lafter = 1 * D
Medium consistency 8 – 16%:
Calming length Lbefore = 1.5 * D or 0.5 m (2 feet) whichever is longer
Calming length Lafter = 1 * D
The KC/5 rotating consistency is not sensitive for disturbances caused by turbulence, allowing installation
immediately after the process pump when the straight pipe section is not available.
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x = Distance between the sensor unit and the
sampling valve is about 500 - 1500 mm (20 - 59")
Sampling
valve
45°
Sampling valve
Sensor unit
Lafter
x
Alternative position
Sensor unit
Lbefore
Tank
L = Straight line
to pipe elbow,
valve or pump
Dilution
water *
Valve
Valve
Lab
sample
Installation location rules:
1. The axis of the sensor and the pump shaft should be perpendicular to each other.
2. Align pump shaft with valve stem.
3. Respect straight pipe section.
Fig.2-1. Installation in a vertical pipe.
Lbefore
Lafter
x
Sensor unit
Sampling
valve
L = Straight line
to pipe elbow,
valve or pump
Tank
Dilution
water *
x = Distance between the
sensor unit and the sampling
valve is about 500 - 1500 mm
(20 - 59")
Valve
Lab
sample
Installation location rules:
1. Align pump shaft with valve stem .
2. Respect straight pipe section.
Fig.2-2. Installation in a horizontal pipe.
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2.3 Dimensions and clearance requirements of the sensor
285
520
304
286
502
8
82
50
33
25
28
67
Figure 2-3. Dimensions of the KC/5 sensor.
BTG Measuring Vessel
460 mm (18")
520 mm (20,5")
520 mm (20,5")
200 mm (8")
660 mm (26")
KPM Measurement Chamber V1.1
375 mm (15")
520 mm (20,5")
805 mm (32")
723 mm (28,5")
Figure 2-4. Clearance requirements of the KC/5 sensor
Note: Always make sure the sensor is easily accessible for service.
At the point of installation, the user should leave a minimum of 805 mm (32”) clearance perpendicular from
the pipe at the point of installation (See figure 2-3), or 723 mm (28,5”) from the edge of a BTG weld-in stud.
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3. Sensor unit and display unit installations
3.1 Process connections
There are 5 alternative process connections:
1. KPM Standard Measurement Chamber with Gate Valve and installation jack. This is the KPM
recommended process connection. See 3.2 for installation instructions
2. Flange installation with KPM Measurement Chamber without Gate valve and Installation Jack
3. Existing BTG measurement chamber (Appendix 3.3 and 3.4)The KPM Adapter fits the Gate Valve
and the Sensor Mounting Assembly to the existing BTG chamber.
4. Mounting bracket for mounting on open vessel or weir (i.e. stuff box or saveall drop chest).
5. Flanged Adaptor for ISO-torq installation without KPM measurement Chamber or new Gate Valve,
and new Installation Jack
3.2 Installing the Measurement Chamber
1. Cut the chamber (Fig. 3-1.) so that the distance from flange to outer surface of pipe is 82 mm/
3,23”, unless cut already by Kajaani Process Measurements.
2. Verify that the curvature of the chamber fits properly over the outside diameter of the pipe.
3. Cut a hole in the side of the pipe to match to the shape of the chamber as shown in figure 3-2. To
prevent fiber debris from collecting on the edge of the cut-out, ensure the edges of the hole are
ground smooth. Debris collected at this location can interfere with proper measurement (See
appendix 1).
4. Place the chamber over the hole in the pipe. Verify that the hole is centered with respect to the
chamber. Fillet weld around the entire perimeter of the chamber to attach the chamber to the pipe.
(See welding drawing appendix 1).
4
A
ø 215 (8.5")
September 2006
ø 71 (2.8")
7.2
ø 168.3 (6.3")
ø 71 (2.8")
ø 168.3 (6.3")
A
130 (5.1")
A-A (PN10/16)
W41040300 V3.01
33 (1.5")
130 (5.1")
33 (1.5")
A-A (PN25)
Page 12 of 67
Figure 3-1. Uncut Measuring Chamber
Curvature of the chamber must match with the process pipe
Cut hole into pipeline
to match with the shape
of the meas. chamber
A
A
ø 215
ø 8.46"
a4
A-A (PN10/16)
a7
82± 2.5
3,23"± 0.1"
Cut the chamber to
match the process pipe.
Center the chamber over the
cut hole and fillet weld around
entire perimeter
A-A (PN25)
82± 2.5
± 0.1"
3,23"
Cross Sectional View of
the Installation Chamber
Figure 3-2. Chamber installation. (see appendix 1)
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3.3 Installation to a BTG MEK process connection
Bolt the KC/5 adapter assembly to BTG weld-in stud or measuring vessel.
Figure 3-2. Adapter assembly for BTG weld-in stud.
Figure 3-3. Installation to weld-in stud or measuring vessel.
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3.4 Installing the gate valve assembly
Note: The gate valve is installed in specific positions for either horizontal or vertical process pipes.
In a horizontal process pipe, the gate valve is installed in the upright position.
In the vertical pipe, the gate valve is placed in the horizontal position.
Gate Valve
Guide Pins (4)
Measurement
Chamber
Bolts (4)
Mounting Flange
Nuts (4)
Insertion Guide
Gaskets
Seal Assembly
Lock Ring
Figure 3-4. Gate valve assembly, horizontal pipe.
Note:
Installation jack must be installed at
12 o’clock position above the sensor.
The sensor interconnect cable
connector is at 3 o’clock position
as in Figure 3-5.
Figure 3-5. Gate valve assembly, vertical pipe.
In the vertical process pipe installation, all parts - from the installation cone to the mounting flange - are
rotated 90 degrees compared to the position shown in Figure 3.4. The direction of the Seal Assembly
remains the same, jack must always be installed at 12 o’clock position above the sensor.
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See figure 3-5, 3-6 and appendix 3.
1. Screw the 4 stud bolts into the Measurement Chamber flange.
2. Install Gate Valve and gaskets to Measurement Chamber. Valve to horizontal position in vertical
pipe, vertical position in horizontal pipe.
3. Place the Mounting Flange assembly (flange with Seal Assembly and Lock Ring preassembled) on
stud bolts, fix the mounting flange to its place with 4 nuts.
4. Check that the gaskets are properly placed in the gate valve. Inspect opening to make certain the
gaskets are not in the way of the sensor.
5. Check that jack mounting holes on Seal Assembly are horizontal (jack must always be installed at 12
o’clock position above sensor), if not remove Seal Assembly and turn to correct position.
6. Check orientation of Lock Ring opening is downwards, so that Radial Locking Bolt can be tightened
(see Fig. 3.6), if not remove Lock Ring and turn to correct position.
Figure. 3.6. Radial locking Bolt orientation.
Safety Warning: Jack and Locking Ring must be secured and attached in place after inserting the
sensor as per chapter 3.5.
Note: Remember to close the gate valve before re-pressurizing the process pipe.
7. Test the gate valve installation for leakages at process pressure.
Mounting the insertion jack
Once the gate valve assembly has been installed and tested under process pressure, the system is ready
for mounting the jack. Install the jack over the seal sleeve with 2 bolts provided. Lock the bolts with locking
pins.
Note: The jack is always installed in vertical position independent of gate valve position.
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Mounting Bolts
to Seal Sleeve
Mounting Bolts
to Sensor
Figure 3-7. KC/5 insertion assembly.
3.5 Insertion of the sensor
Preparing for insertion
1. Check that the inside of seal sleeve is free of dried pulp and debris. Remove any material inside
2. Check that the O-ring inside the seal sleeve are secure and undamaged
3. Lubricate O-ring surfaces with grease to reduce friction (Vaseline or silicone grease can be used for
lubrication)
Inserting the sensor
If the sensor has previously been in use make sure the sensing element and seal sleeve inside are
clean. Every time the KC/5 is taken out of line, the seal sleeve and sensing element should be
rinsed with clean water to remove any pulp and debris.
Note: Before inserting the sensor the first time, please read the chapter 6.2. before insertion to
follow correct setup procedure depending on the application.
Note: To prevent the sensing element from pushing against the gate valve, make sure that the jack
is in FULLY OPEN position.
1. With the gate valve still in the closed position, lift and slide the KC/5 unit into the seal sleeve until the
bolts in the jack can be mounted to the sensor body. (See figure 3-8). The jack must be completely
open.
2. Fasten sensor probe to the insertion jack with two bolts and insert the locking pins to prevent the bolts
from turning by vibration.
3. Connect the seal water to the sensor.
4. Open the gate valve.
5. Jack the sensor in until the insertion depth adjustment ring stops against the locking ring.
6. Fasten the locking screw to lock the sensor safely into its measurement position.
7. Connect the interconnect cable to the Sensor
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Seal
Sleeve
Jacking
Screw
Locking
Ring
Jack
Bolt
Hole
Depth
Adjustment
Ring
Seal Water
Seal Water
Inlet
Figure 3-8. Insertion of the sensor unit.
Safety Check after each insertion to the process line
Safety Warning: Jack and Locking Ring must be secured and attached in place after re-inserting
the sensor.
Proper installation of the locking ring is required to prevent:
1. Injury – secures the sensor in place to keep it from accidently backing out of the process.
2. Sensor Damage – stabilizes the sensor and minimizes vibration that may damage the jack and
the sensor unit.
AT ALL TIMES, IT IS CRITICAL TO ENSURE THAT THE LOCKING RING IS SECURELY TIGHTENED IN
PLACE.
The locking ring secures that the sensor does not come accidentally out from the process and that the
sensor doesn’t vibrate inside installation parts. Excessive vibration can damage the jack and the sensor. It
is important the Locking Ring is securely tightened.
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Figure 3-9. Locking ring of the Sensor
The KC/5 sensor locking ring has to be tightened securely following way:
1. Make sure the orientation of the Locking ring is so that the Radial Locking Bolt can be tightened with allen
key, if not, rotate the Locking ring on the Insertion Housing so that the Radial Locking Bolt is accessible.
2. Tighten the Radial Tightening Bolt of the Locking Ring.
Figure 3-10. Radial locking of the Locking Ring.
3. Tighten the Locking Ring Fastening Bolts to lock the sensor to the Insertion Housing assy.
Figure 3-11. Fastening the Locking Ring to the Insertion Housing.
Note: Locking ring has to be tightened every time the sensor is installed after maintenance.
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3.6 PN25 Installation
Note: The standard Gate Valve Assembly is designed for pressures up to 16 bar (240 psi). PN25
(360 psi) requires high pressure Jack, PN25 (360 psi) Gate Valve, high pressure insertion housing,
and a special adapter for the sensor to mount the Jack to the sensor.
PN25 (360 psi) Gate Valve
PN25 (360 psi) Jack
PN25 (360 psi) Adapter
H41040375 V1.0
PN25 (360 psi) Lock Ring
PN25 (360 psi) Insertion Housing
PN25 (360 psi) Measurement
Chamber
Figure 3-12. PN25 (360 psi) Installation Parts.
3.7 Seal water connection
KC/5 drive shaft is equipped with mechanical seals (double seal, tandem sealing system). The seal
manufacturers recommend flushing of seals with water to extend the seal life. The water provides flushing,
lubricating and heat transfer.
KC/5 has two alternatives for seal flushing
1. Low pressure water flushing.
2. Self contained seal cooling and lubrication system (reservoir)
3.7.1. Low pressure water flushing
It is recommended to connect flushing water if the water quality is good enough to keep the seal water
system clean. Mechanical seals last longer with seal water when pulp contains fillers. The rate of flow is
limited by the flow regulator. Make sure that seal water flow can be checked and monitored easily.
Recommended water pressure is 1.0 -10 bar (15 -150 psi), max. particle size 200 µm. Flow is 0.5 to 2.0
l/min (0.13 to 0.5 US gal/min) within specified pressure.
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Connect the seal water to the ¼” male fitting of the sensor using flexible ¼” reinforced plastic tube. Flexible
tube must be used to facilitate the move of the sensor.
Install a shut-off valve close to the transmitter. Connect another ¼” reinforced plastic tube to the outlet, and
draw it to the floor drain and fasten it just above the floor outlet so that the flow can be observed.
It is a mandatory to install an anti-siphon prevention tube to prevent siphon phenomena in case of seal
water loss.
Reinforced flexible plastic tube
8/6 mm Elbow fitting
Anti-siphon tube
Flow regulator
0,5 - 2 l/min
0,13 - 0,5 gpm
Valve
Open flow to channel
Note: As long as the seal
water is running during a
process shutdown there is no
need to turn off the sensor
motor
1 - 10 bar
15 - 150 psi
Figure 3-13. Low pressure water flushing arrangement.
3.7.2. Self contained seal water system
The self containing cooling liquid system is optional. This approach is recommended if water quality is poor.
The cooling water reservoir is mounted in the insertion jack and connected with flexible tube to the seal
water inlet. Volume is 1 liter (1/4 US gallon), use drinking water to fill the reservoir if ambient temperature
stays above 0ºC (+32ºF). If freezing conditions are possible, use glycol/water mixture 50/50%
Water reservoir is emptied when ever tubes to the sensor are decoupled. Refill the reservoir before power
to the sensor is turned on.
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Figure 3-14. Self contained seal water system.
3.8 Insertion depth adjustment
KC/5 sensor can be installed at adjustable depth into the process. To move the depth adjustment ring,
loosen the set screws, slide the adjustment ring to desired position and relock the set screw again. Figure 310 gives most commonly used values. Unless specified in the order, KC/5 comes with standard depth
adjustment for KPM Installation Chamber. With MEK adapter sensor need to be fully inserted.
Depth adjustment becomes useful if flow pattern or consistency profile changes for one reason or another.
By inserting the sensing element deeper inside one can avoid the layer where consistency profile varies.
A
Depth adjustment A:
KPM Chamber 12mm
BTG Adapter 0 mm
Figure 3-15. Insertion depth adjustment.
3.9 Installation of the display unit
The display unit can be located anywhere near the sensor unit so that it can be easily accessed by mill
personnel. Connection cable standard length is 10 m (33’). Protection class of the display unit enclosure is
IP66 (NEMA 4X). Mount the display unit to the wall with four (4) screws.
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150
6.9"
Ø6
1/4"
195
7.7"
400
15.7" 350
11.8"
200
7.9"
Figure 3-16. Dimensions of the display unit.
4. Electrical connections
4.1 Display unit connections
The display unit has two functions: to supply 12/48 VDC power to the electronics/direct drive motor, and to
serve as an easy-to-use interface. It is connected to the sensor unit via 10 m (33 ft) cable. Connections are
shown in figure 4.1.
Wire the display unit as follows:
1. Open the box cover. The connectors are in the connection board.
2. Install the interconnect cable coming from the sensor unit and 4 - 20 mA cable coming from DCS to
terminals as shown in figure 4.1. The 4-20mA can be powered by sensor (default) or by DCS, see fig
7.14 how to change the setting.
Note, if powered by DCS polarity is reversed (- pin 12, + pin 13).
3. Connect 220/110 VAC (85-264 VAC)
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+
-
Grade selection codes
Grade pin 14 15
16
SW
HW
TMP
CTMP
GW
Recycle
Eucalypt
User def
0
1
0
1
0
1
0
1
0
0
1
1
0
0
1
1
0
0
0
0
1
1
1
1
DCS
Analog input
4 - 20 mA
Binary Output
+24 VDC
Grade selection
Sampler
+24 VDC
Binary Output
+24 VDC
Process stop
Binary Input
+24 VDC
Alarm
Display unit
S AMPLE
ES C
Sensor Connections
DCS Connections
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Interconnect cable
10 m (33')
shield
current loop +
current loop grade 0 +
grade 1 +
grade 2 +
grade shield
sample +
sample shield
process stop +
process stop alarm on
alarm GND
alarm off
shield
current loop +
current loop sensor supply +12 VDC
sensor supply GND
RS485 A
RS485 B
pwm
motor supply +
motor supply -
ENTER
ON
L
N
9
8
10
7
6
5
4
3
2
1
OFF
110/240 VAC
50/60 Hz
Sensor unit
Figure 4.1. Electrical connections.
4.2 Sensor unit connections
Sensor unit is connected to display unit via supplied interconnect cable. All the internal connections are
factory made.
1. Couple the seal water tubes, see fig 3-8. Water must be present on seals before power is connected
to the system.
2. Plug in the quick connector at motor end of the cable.
5. Operating and setup instructions
5.1 Operation of the KC/5 – operator interface
All the functions of the KC/5 are easily configured through the clear screen (See figure 5.1). Operation of
KC/5 is menu driven. The arrow keys allow movement between the menus.
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The menu structure is divided into three main function blocks: Calibration, Set-up and Maintenance. The
Factory Settings can be used to change some default parameters in special cases. The menu structure of
the KC/5 user interface is shown in the next chapter.
SW
Cs: 3.5 %
OUT 15.4 m A
1
2
4
3
5
Figure 5.1. The KC/5 user interface.
1. The display is 2 lines high x 16 characters in length. Main display shows both consistency value in
percent and the analog output in mA. Display also shows current grade in the left upper corner. Menu
display returns to main display automatically if not operated in 30 seconds.
2. Sample key. When activated, a 30 second countdown timer starts to show so as to identify when to
take the sample. The display unit stores date, time and the measured consistency value averaged
over 30 seconds time in its memory for later comparison to the lab values. This way it is easy to
identify laboratory samples so that it corresponds in time to the consistency readings of the sensor
unit.
3. Arrow keys - Arrow keys are used to move between menus, move cursor, or change values. Please
refer to menu structure for more information about the arrow keys.
4. Esc key - press to cancel changes and/or return back to the previous menu.
5. Enter key - press to accept data and input changes.
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5.2 Menu structure
SW
Cs 0.00 %
Out 4.0 mA
ENTER PASSWORD
000
APPEARS IF PASSWORD OTHER THAN 000
PASSWORD IS SET IN SET-UP MENU. (PASSWORD 633 WORKS ALWAYS)
CALIBRATION
Change zero
and slope
Zero:
Slope:
xx.x
xx.x
Lab values
0000-00-00
Csxx.x
0:00
DIF 00.00
Enter
lab value
0000-00-00
Csxx.x
0:00
DIF 00.00
Delete sample
enter confirms
SET UP
MAINTENANCE
Old zero:
Enter new
xx.x
xx.x
Old zero:
New zero
xx.x
xx.x
0000-00-00
Csxx.x
0:00
LAB 00.00
Old slope:
Enter new
xx.x
xx.x
Old slope:
New slope
xx.x
xx.x
FACTORY SETTINGS
(requires password 633)
Calibration
calculation
Start up
x sample ok
enter continues
S: xx.xx
std. error:
Z: xx.xx
x.xx
TORQUE OFFSET:
T: XX.X O: +/- XX.X
MEAS. TORQ. OFFSET
ENTER CONTINUES
Edit Torque Offset
xxxx mNm
Edit Torque Offset
xxx mNm
Target Cs
ENTER TARGET Cs:
xx:x %
Edit Target Cs
xx:x %
September 2006
Edit Target Cs
xx:x %
W41040300 V3.01
WAIT A MOMENT
RESULT: XX.X mNm
ENTER CONFIRMS
S=
Z=
Enter confirms
S=
Z=
Enter confirms
Page 26 of 67
CALIBRATION
SET-UP
GRADE: SW
LOCAL CONTROL
Grade: XXX
S: XXX
Z: XXX
MAINTENANCE
LOW LIMIT:
xx.x %
OLD LIMIT:
ENTER NEW:
XX.XX
XX.XX
FACTORY SETTINGS
HIGH LIMIT:
xx.x %
OLD LIMIT:
ENTER NEW:
XX.XX
XX.XX
OUTPUT FILTER:
XX s
EDIT FILTER:
s
XX
SET CLOCK
year-mo-dd hh:mm
EDIT DATE & TIME
year-mo-dd hh:mm
GRADE SELECTION
MODE: LOCAL
SELECT
MODE: REMOTE
MENU LANGUAGE:
ENGLISH
SELECT LANGUAGE
ENGLISH
ELEMENT TYPE:
PADDLE
SELECT
SELECT ELEMENT
ELEMENT
8-PIN
PADDLE
ERROR OUTPUT
CURRENT: NO EFF.
SELECT ERROR
CURRENT: 3.50 mA
PRC.STOP OUTPUT
CURRENT:
SELECT PRC.STOP
CURRENT: 4.00 mA
PASSWORD
000
EDIT PASSWORD
000
AUTO REVERSE
OFF
EDIT GRADE NAME
4-PADDLE
GRADE:
S: X.XX
SW
Z: XX.X
GRADE:
S: X.XX
SW
Z: XX.X
PLANE
AUTOZERO
SELF CLEANING
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SET-UP
MAINTENANCE
DEVICE
IDENTIFICATION
FACTORY SETTINGS
CHECK ON-LINE
SIGNALS
DEVICE TYPE:
KC/5
OPTIC:
CPU
XXC XXF
YYC YYF
FRICTION
x.x Nm
POWER:
MOTOR:
x.x V/ xxC
x.x V/x.xA
SERIAL #
TAG
TEXTPROM
FIRMWARE VERSION
VERSION
HART
ID
BINARY INPUT
STATUS:
OOOO
RAW:
xxxxxx
SPD: xxx.x RPM
N:xxxx
M: xxxx
DATALOG SINCE
yyyy-mm-dd
hh:mm
Cs min:
Cs max:
T: yyyy
Cs: xx.x%
xx.x %
xx.x %
mNm min: xxxxx
mNm max: xxxxx
OPTIC
xx C
MIN:
yy F
OPTIC
xx C
MAX:
yy F
>1 Nm SHOCK
COUNT
XX
Date Time
Value Duration
<-100 mNm SHOCK
COUNT
XX
Date Time
Value Duration
RESET LOG DATA
ENTER CONFIRMS
TORQUE SETUP
LOW TORQUE
xxxxxxx / xx mNm
EDIT LOW BRAKE
xxx mNm
VALUE:
HIGH TORQUE
xxxxxxx / xx mNm
SIGNAL SIMULATION
CHECK ALARMS (XX)
RESET TO FACTORY
DEFAULT VALUES
September 2006
EDIT HIGH BRAKE
xxx mNm
VALUE:
Cs SIMULATION
SET Cs: xx.x %
OUT xx mA
mNm SIMULATION
xxx
SET mNm:
Cs xx.xx% xx.xx mA
Alarm 1
APPLY xx mNm
TORQUE BRAKE
RESULT:
xxxxxxx
ENTER CONFIRMS
EDIT RAW VALUE
xxxxxx
EDIT
APPLY xx mNm
TORQUE BRAKE
RESULT:
xxxxxxx
ENTER CONFIRMS
EDIT RAW VALUE
xxxxxx
EDIT
xxxxxx
xxxxxx
2 3
PRESS ENTER TO
CONFIRM RESET
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SW
Cs 0.00 %
Out 4.0 mA
CALIBRATION
SET UP
MAINTENANCE
FACTORY SETTINGS
PASSWORD
(633)
EDIT SN
XXXX
SERIAL NUMBER
XXXX
DEFAULT ELEMENT
PADDLE
CURRENT OUTPUT
CALIBRATION
PLANE
FRICTION ALARM
LIMIT: 1.5 Nm
CHECK TEMP COMP
FACTORS
TEMP FACTOR 0
0C
xx
MOTOR CONTROLS
September 2006
4-PADDLE
EDIT VALUES
S: xxxx Z: xxx
FRICTION ALARM
LIMIT: 1.5 Nm
TEMP SENSOR
DIAGNOSTIC
SELECT DEFAULT:
PADDLE
1
9
EDIT FACTORS 0-9
00C
0000
RPM SET POINT
xxx
RPM SET POINT
xxx
MOTOR DIRECTION
CW +/- XX mNm
MOTOR DIRECTION:
CW
CCW
AUTO REVERSE
10s / 3 min / 0.8
SET AUTO REVERSE
XX s / XX min / X.X
CONTROL LOOP
SPEED: 40
EDIT CONTROL LOOP
SPEED: XX
157/187/ORD ID:
1059736B0008012
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5.3 Set-up
Perform following checklist before configuration of the sensor:
1. Check that the sensor unit is properly inserted into the process.
2. Check that the seal water is flowing.
3. Check that the interconnect cable and power cable to the sensor unit are connected as per the wiring
diagram.
4. Turn on the switch in display unit. The motor starts to run unless “process stop” input is activated.
For normal installation, follow the steps in the KC/5 set-up checklist as follows:
1. Select grade:
The user can change grade manually or by binary inputs from a remote device. The current grade selection
mode (local or remote) is shown below the menu name. Each element has a predefined S (Slope) and Z
(Zero) parameters for 8 different pulp grades (SW, HW, CTMP, TMP, GW, RECYCLE, EUCALYPT and
USER DEF).
Sensing
Element:
Grade:
SW
HW
TMP
CTMP
GW
Recycle
Eucalypt
User def
Paddle (Standard)
2 Paddle
S
Z
1.6
-1.9
1.7
-1.5
1.6
-1.9
1.5
-1.9
1.2
-0.6
1.9
-2.1
1.9
-2.1
2.0
-5.0
4-Paddle
S
1,9
2,0
1,9
1,8
1,5
2,1
2,1
2.0
Plane
Z
-3.4
-2.9
-3.4
-3.2
-2.2
-3.5
-3.5
-5.0
S
1.5
1.5
1.5
1.5
1.2
1.8
1.8
2.0
Z
-1.5
-1.0
-1.5
-1.8
-0.8
-1.5
-1.5
-5.0
Table 6.1. Default values for S and Z.
Grade names may be edited (see Menu Diagram, Section 5.2). Edited grade names remain in use until
factory reset is activated, at which time, the original factory settings are restored in the language selected.
Factory default values are stored permanently in KC/5 memory.
When the KC/5 is started for the first time, the factory default values are in use. The user may then change
these parameters as necessary. The KC/5 will use the most recent parameters selected for each grade.
2. Select low limit of measurement span
The low limit may be set between 0.00 and 19.99 %/Cs. This value corresponds to output current 4 mA.
Low limit must be smaller than high limit.
3. Select high limit of measurement span
The high limit may be set between 0.00 and 19.99 %/Cs. This value corresponds to output current 20 mA.
High limit must be larger than low limit.
4. Output filter
The user may elect to filter out process noise, or abnormal spikes, from the output signal by using this
function. Filtering time is expressed in seconds (default = 10 seconds).
5. Set clock
Date and time are given in “YYYY-MM-DD and HH:MM” format.
6. Grade selection mode
The user may choose either local selection of grade type or remote selection using binary inputs.
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7. Select menu language
Select between English (default) and Finnish.
8. Select sensing element
The user selectable sensing element types are Paddle (default), 4-Paddle and Plane. The user has to select
the element that is installed on the sensor.
9. Error output
The User may select one of four responses when the KC/5 detects an error. These are:
•
NO EFF: measured value is outputted even through the value of output can be erroneous
(default).
•
3.5 mA: analog output goes to 3.5 mA during error.
•
22 mA: analog output goes to 22 mA during error.
•
FREEZE: output freezes on the last accepted measurement value.
See more information from chapter 7.2 - Check alarms.
10. Process stop output
When the “Process stop” input is activated the KC/5 sensor motor stops running. The user can select how
the output behaves in this case. Alternatives are:
•
4.0 mA: analog output goes to 4.0 mA during stoppage.
•
20 mA: analog output goes to 20 mA during stoppage.
•
FREEZE: output freezes on the last accepted measurement value.
•
11. Password
If other than 000 is selected this password is required to move from the main display to the menus. 633
overrides any set password and can be used always.
12. Auto reverse
When auto reverse is activated the motor runs at set interval in reversed direction. There are 3 options to
select from:
•
“OFF”: Motor runs all the time in the same direction
•
“AUTO ZERO”: Motor runs at set interval for a certain time in reversed direction. The measured
reversed torque is used for automatic zeroing of the torque measurement system. The reversed run
frequency and time are set in the “factory settings” menu.
•
“SELF CLEANING”: Motor runs at set interval for a certain time in reversed direction. No
automatic zeroing is done. The purpose to remove wrapped material from the sensing element.
6. Calibration
A separate set of calibration values is needed for each type of sensing element and pulp grade measured.
The KC/5 may be calibrated against laboratory values by taking samples or by choosing values from the
sensor memory.
Initial calibration of KC/5 consists of following steps:
•
A. “Torque Offset”: While the process is running in the normal conditions the motor is run in revered
direction with the sensing element inserted in the measurement position. KC/5 calculates the torque offset
for zeroing the system. Press ENTER to confirm. (See 6.2).
•
B. “Single-Point Calibration”: KC/5 tunes calibration parameters Slope (S) and Zero (Z) based on one
laboratory sample (see Section 6.3).
•
C. “Calibration”: Fine-tuning of the calibration using multiple points is described in Sections 6.4-6.6.
For standard installations, follow Steps A and B.
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6.1 Calibration menu
Consistency calibration is made by linearized curve.
Cs = S x M + Z
Cs=Consistency, S = Slope, M = Linearized measurement and Z = Zero.
1. Change zero and slope:
The user can review and adjust the Z and S values from this display setting. Zero Z can be adjusted from 99.99 to +99.99. Slope S can be adjusted from 0.00 to +19.99.
2. Lab values:
The user may review the last 10 samples stored in the memory; including sampling times, measured values,
and lab values. Through this display the new lab values are entered or old values edited.
Use the delete (“DEL”) function to remove old sample..
3. Calibration calculation:
The KC/5 is able to calculate new Z and S values based upon a minimum of three (3) sets of stored
calibration data.
Recommendation: Use a spreadsheet program (e.g. Excel™) to record and track calibration data in place of
using KC/5-aided calculation. The spreadsheet provides the user better visibility to data and simplifies
removing of unreliable information.
4. Start up:
1. Torque Offset: To zero any offset in torque measurement system. Used normally in the initial set up
of the unit
2. Edit torque offset: The zero adjustment offset received in the above procedure can be edited. Used
only in special cases.
3. Target Cs: Used to quickly start-up a new unit. See 6.3 for details.
4. Edit target Cs: To edit the “presumed” consistency. See 6.3. for details
6.2 Torque Offset (Zeroing of the torque measurement system)
A: Low consistency applications below 5% Cs.
Insert the sensor into the process. Make sure that the process is running in the normal operating conditions.
1. With the sensor in-line and the process running, seal water flowing, turn power “On.”
2. Go to “Start up – Torque offset – Meas. Torq. Offset,” and press ENTER.
3. The display asks to “Wait a moment” while it is checking the zero point of the torque measurement
system.
4. Result of the zero check is shown in the display. Press ENTER to complete the zeroing procedure.
Write down the result.
5. Repeat the Meas. Torq. Offset procedure. Compare the results, if difference is bigger than 2mNm,
proceed according the following procedure: B: Medium consistency applications.
B: Medium consistency applications above 5% Cs.
1. Remove the sensor from the process according chapter 7.5, Removal of the sensor, or make sure
the process line is empty or filled with water.
2. Hold the sensor on your lap and make sure the sensing element can rotate freely.
3. Go to “Start up – Torque offset – Meas. Torq. Offset,” and press ENTER.
4. The display asks to “Wait a moment” while it is checking the zero point of the torque measurement
system.
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5. Result of the zero check is shown in the display. Press ENTER to complete the zeroing procedure.
Write down the result.
6. Note: sensing element has to rotate freely. Anything touching the sensing element will interfere with
measurement
7. Reinstall the sensor according Chapter 3.5, Inserting the sensor.
6.3 Single-point calibration
Use the “Target Cs” procedure in the “Start-up” Menu to quickly start-up a new unit.
•
1. Go to “Target Cs” menu while KC/5 is measuring the consistency (Cs%) value of the process.
2. “Enter” the ‘presumed’ consistency of the process. KC/5 averages 30 seconds of measured torque
and adjusts calibration parameters S and Z to match the consistency value of the process. While
averaging, the display reads “Wait a moment”.
3. Take a sample while KC/5 is averaging and perform laboratory analysis to verify the ‘presumed’
consistency settings.
4. If lab consistency differs more than ±10 % from the ‘presumed’ consistency, go to “Edit Target Cs”
and change the original, ‘presumed’ consistency to the correct value and repeat tuning by selecting
“ENTER”.
5. Continue calibration fine-tuning by following steps described in Sections 6.5-6.6
6.4 .Zero adjustment
After initial calibration described in chapter 6.2-6.3 only zero adjustment (offset change) is usually needed.
This is done by changing Z value.
1. Take the sample.
2. Read the transmitter’s consistency reading when the sample is taken.
3. Make laboratory analysis.
4. Adjust Z to make lab and transmitter readings match.
Example:
KC/5 reading
Lab result
New Z = old Z + 0.3
3.2%
3.5%
If old Z = -7.0 New Z = -6.7
6.5 Sampling procedure
Laboratory samples are taken and stored in the KC/5 memory as follows:
1. Press “SAMPLE” button. The display indicates “Sampling Time Left in Seconds”. During a 30second countdown, the KC/5 averages 30 seconds worth of measurement value and stores that data
and the time of sampling, into the calibration data memory.
2. You must take the laboratory sample during this 30-second count down to match the stored
data.
3. The KC/5 display indicates: measured Cs %, the linearized measurement M, and the MIN-MAX
value. MIN - MAX value identifies the stability of the process during the sampling time. If the
consistency value is unstable during the sampling time, the sample extracted from the process will
not reflect the real consistency value – this sample is not a reliable basis to determine KC/5
calibration. Discard this sample. REPEAT the sampling process until a uniform sample is obtained.
The measured value is stored in memory by pressing “ENTER” or automatically after 5 minutes
have elapsed. By pressing “ESC” the sample value is discarded, and the display returns to the main
menu.
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4. Analyze the sample in laboratory.
5. Enter the laboratory results into the KC/5 as follows:
•
a.
Select “Lab Values” from “Calibration” menu. The display indicates the time of the
last sample and the Cs average and the variation in the reading (“DIF”) during the time of sampling. Use the
“ENTER” button to scroll between “DIF”, “Lab Cs%”, or “M” values. When the value of “DIF” is > 1 % Cs, the
extracted sample should be rejected, and not used, by pressing “ESC”.
•
b.
Scroll with “↑” or “↓” buttons to reach appropriate sample data. “Time” provides
identification of the sample.
•
c.
Press “→” button to select desired data. Menu prompts “ENTER LAB VALUE”.
Enter by the “→” button, enter the laboratory value, then press “ENTER” to confirm the value or “ESC” to
discard it.
•
d.
When the sample data is not acceptable (for example, there is a large swing in
consistency during the sampling), go to “DELETE SAMPLE” mode and press “ENTER” to discard the
unacceptable sample values from KC/5 memory.
6.6 Changing calibration parameters
There are two possible ways of adjusting the calibration values:
1. Change Z and S manually.
2. Ask KC/5 to calculate a new Z and S based on stored calibration data.
6.6.1. Manual adjustment
Manual adjustment allows the operator to change the “Z” and “S” of the curve in use. This is performed in
the “Calibration” menu.
To achieve the highest degree of accuracy in calculating calibration parameters, KPM recommends use of a
spreadsheet-type program. Contact KPM for a copy of spreadsheet file compatible with Excel.
6.6.2. Transmitter calculated parameter change
When minimum of 3 laboratory samples have been collected and results entered into KC/5 memory, the
transmitter is ready to calculate “new” calibration parameters. Make certain that Cs varies ± 2% of set point
to ensure that the calculation is accurate. For a more accurate calibration, KPM recommends the use of
minimum five (5) sets of sample data.
1. Select “Calibration” menu. Use the “→” button to go to “Calibration calculation”.
2. The display shows “# SAMPLES OK ENTER CONTINUES”. The value # must be 3 (three) or higher
for the calculation to be performed. When fewer than three samples are entered, the display indicates
“Invalid Samples”. KPM recommends extracting minimum five (5) sets of sample data spread at ±
2% Cs to determine correct calibration information
3. Press “ENTER” to calculate new S and Z using the laboratory samples. The display shows the new
values, and the estimated error of calibration.
Please check that S is at realistic level, typically 1,5 -5.0. Limits to enter new value are 0.0 – 19.99. If
the result is unrealistic, discard and do not use the new parameters. Troubleshoot the calibration
data.
4. Press “ENTER” to accept the new calibration parameters or press “ESC” to retain the old values.
5. The program automatically returns to the Main menu.
Note! KC/5 requires a minimum of 3 laboratory samples to calculate calibration parameters. The
calibration data is stored in a stack of 10 data sets that follow the FIFO (First In First Out) principle.
When calculating calibration parameters, the KC/5 uses all data stored in memory at that time. The
“Estimated Calibration Error” indicates the reliability of the new data and helps determine the
validity of the calculated parameters. Therefore all unacceptable sample data must be deleted from
memory.
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7. Maintenance
7.1 Regular maintenance of the KC/5
Safety Warning: Jack and Lock Ring must be secured and attached in place after re-inserting the
sensor, as per chapter 3.5.
The KC/5 requires no regularly scheduled maintenance other than checking that the seal water flow rate
stays between 0,5 – 2l/min (1/8 – ½ gal/min. When using the seal water reservoir, keep the water level
between 30%-70% full.
Seal water reservoir (optional, when mill seal water is not suitable)
The mechanical seal generates heat and requires cooling and lubrication. The seal water reservoir provides
water to protect he seal when mill seal water cannot be used.
Note: KPM recommends turning off the KC/5 motor during long process outages using “Process
Stop Output” (see Figure 4.1, Electrical connections, “DCS Connections”.
Check the seal water reservoir regularly – at least every other week, to determine the appropriate
replacement rate. The reservoir should be kept above 30% full. If fibres appear in the reservoir, drain
immediately and refill – fibres plug fluid channels and prevent seal fluid circulation. A large increase in fibre
quantity indicates that the front seal may need replacement.
Note! It is normal for mechanical seal to leak, but this should be kept at a minimum for longer seal
life. Seal water may become cloudy when fibres, fines or fillers mix with water.
7.2 Maintenance menu
The Maintenance Menu allows the user to perform two important functions:
•
To evaluate performance of the KC/5.
•
To evaluate the behaviour of the process.
1. Device identification:
The user may view the following product information:
•
device type
•
serial number
•
tag number
•
firmware version.
•
textprom version
•
Hart ID
•
The tag number can be edited by the user. All other information is stored in permanent memory.
2. Check on-line signals:
The user can view following values in real time:
•
sensor temperatures (optics and CPU) in Celsius and Fahrenheit
•
friction [Nm]
•
power module output voltage and temperature (V) (C)
•
motor voltage and current (V) (A)
•
binary input status (O = open, I = Closed)
•
raw-signal from sensor (RAW)
•
motor speed (RPM) (SPD)
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•
•
•
•
•
torque (N)
temperature compensated torque (T)
linearized measurement signal (M)
consistency measurement (Cs % = Slope x M + Zero).
Displayed Torque (N) is the sum of measured torque + torque offset.
3. Data log since:
The user may view the following data:
•
Cs min/max
•
mNm min/max
•
optics temp min/max
•
the number of abnormal shocks (hits) on the sensing element (high and low force ranges < –100
mNm and > 1 Nm).
•
The time since the last reset is shown with the data. The data logs may be cleared in the “Reset
Log Data” menu.
4. Torque setup:
Used to bench calibrate the sensor after service. Calibration is performed using a torque brake. The zero
level is set when sensing element is spinning freely in air.
1. Set Low Torque, when in air, set 0,0 mNm
2. Perform Low Torque set up
3. Set High Torque value specific for the torque brake used.
4. Perform High torque set up
Low torque: Displays the existing low torque calibration numbers – raw value and used torque. Torque
value may be edited. Use to re-zero the sensor signal. The “New Low Torque” calibration value is
accepted by pressing “ENTER” button. Calibration is cancelled by “ESC.
High torque: Displays the existing high torque calibration numbers – raw value and used torque. Torque
value can be edited. Recalibration requires user acceptance (“ENTER”).
5. Signal simulation:
The correct output signal performance (4 to 20 mA) may be checked with this function. The simulated output
current corresponds to the consistency value and output scaling. Simulated signal may be either the Cs%
reading (“CS simulation”) or the mNm (“Torque simulation”) corresponding to 0-999 mNm.
6. Check alarms:
Current active alarms (count of alarms shown in brackets). User can view following internal alarm flags:
Alarm name
Possible cause
Action
Temp sensor
error
Temp too high
Temp too low
Pr. Eeprom empty
Gap too small
Gap too big
Torque setup err
Cs>high limit
Cs<low limit
No signal
Temperature sensor failure.
Temp compensation not used
Sensor overheating, >80 C
Temp < 0 C (32 F)
EEPROM, optics board failure; loose wire
The optical discs out of alignment, check spring
The optical discs out of alignment, check spring
Torque set up failed; sensitivity out of limits
Consistency over set range
Consistency below set range
Optics board failure, discs overlapping, loose
wire
Output set to alarm mode
Output to 20 mA
Output to 4 mA
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Motor jam
Motor Problem
Power over temp.
High friction
Power problem
Too high friction; seal tight, bearing worn out
Motor RPM < set value; bearing, power supply
Power supply to motor overheating
Friction >1,5Nm; bearings or seal damaged
Power supply, Hall-sensors of motor,connection
cable
7. Error messages:
In addition to “Alarm” messages, KC/5 indicates the following “Error messages:
Message
Possible reason
Invalid samples
Laboratory result not in memory.
Consistency varies more than 1 Cs % during sampling.
Fewer than three (3) samples in memory.
Slope too high
Calculated Slope in calibration is greater than 19.99.
Result will be discarded
Invalid Cs
Editing of consistency (in torque tuning) denied – S or Z has been
changed; see 5.4
AUTO RVS
Motor runs counter-clockwise in “Auto-reverse” mode
8. Reset to factory default values:
The user may reload the default values of S (Slope) and Z (Offset) for all pulp grades. Default values are
shown in Table 6.1. Other parameters that are returned to factory values are: sensing element type, output
filtering, and local grade selection mode. Grade names are changed to default in the selected language.
7.3 Motor controls
These functions are under the “Factory settings”-menu. Password 633 is required to enter.
1. Change of rotation speed:
The user may change RPM of the motor within 300-650 RPM. Display shows set speed, actual speed and
torque value. By pressing “Enter” the set value becomes permanent speed.
Measurement sensitivity and signal-to-noise ratio improves when RPM is increased. As a rule of thumb:
Cs range
Rotation speed
<3%
>3%
600 RPM
420 RPM
2. Change sensor rotation direction:
The user may change the direction of the motor rotation. Normal direction is ClockWise (CW) viewed from
the motor end of the sensor. Counter ClockWise direction is indicated as CCW.
Direction change is useful to remove wrapped material from sensing element. Reverse torque reading is
indicated only. This reading helps to determine if the sensing element has dislodged foreign materials.
Exiting the “Motor Controls” menu automatically returns the direction to CW).
3. Auto-reverse
The rotating direction of the sensor may be changed manually, or programmed to automatically reverse
after a pre-set interval.
The parameters are set in the form of A sec / B min / C:
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A: selection of the time of reversed operation (default 10 sec). Time of reverse is adjustable from 1-120
seconds at 5-second intervals.
B: how often reversed operation occurs (default 3 min). The time is adjustable up to 180 minutes.
C: when auto-zero has been selected (set up menu) this number sets how much of the measured zero
point shift of the torque is corrected at a time. 0 means 100%, 1 means 0%. Default is 0.8 (= zero point
deviation is corrected in 20% steps).
NOTE: “Auto-Reverse” is interrupted, when:
•
The “Sample” button is activated.
•
Display unit is not showing the Main display window - KC/5 is operating. The interrupted “AutoReverse” function restarts one minute after returning to the required position.
The Output signal holds the last value displayed when “Auto-Reverse” is activated.
Use the “Auto-Reverse” mode in recycled pulp applications to remove foreign matter that may attach to the
sensing element. Reversing the rotation dislodges this material from the sensor. This helps reduce the need
to remove the sensor from the line to clean the sensor head.
7.4 Troubleshooting
The KC/5 features useful diagnostic functions to help find defective components. These easy-to-use
diagnostics are located in the “Maintenance / Check on-line signals” section. First, check the following:
1. Motor is running (RPM is as set).
2. Friction is less than 1 Nm. (FRICTION)
3. Motor voltage is 24 – 48 VDC (POWER)
If these values are not correct, use the wiring drawing (Figure 7-14) to help locate faulty component(s).
Check following voltages:
AC/DC Power supply outlet voltage is between 48±2 VDC. Measure at the AC Power Connection Board.
Motor Supply voltage is 24-48 VDC. Measure at Connection Board AND at the Sensor Board.
Sensor Supply Voltage is 12 VDC ± 1 VDC. Measure at Connection Board AND at the Sensor Board.
Problem
Potential source of problem & solution
A. Motor is not running
1. Check that the process stop binary input is not activated (if active
main display reads “Process stop”)
2. Check the power switch in display unit is ON
3. Check fuse in the display unit and reset if needed. (fig 7.14, 7.17 &
4.1)
4. Check that drive shaft is not jammed
•If jam is reason alarm message reads motor jam
•Check from on-line signals if motor tries to start (motor current)
•Rotate drive shaft from sensing element and try if it helps
•If not, replace mechanical seal or bearing assembly
5. Check power to the motor. See figure 7.14. (pins 9 & 10)
•If there is no power to the motor replace AC/DC power unit.
•If power ok change sensor board (See section. 7.13).
B. Erratically spinning
sensing element.
1. Sensing element needs to be re-aligned (See section 7.10). Or
damaged one changed
2. If gate valve has been closed while sensing element is inside it, the
moment shaft might also be bent. Check straightness of the head of
the moment shaft. Replace moment shaft if not straight.
C. Seal water reservoir
Refill reservoir to line level using good quality water.
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has a low fluid level.
D. Seal water is dripping
from drain hole
If the rear seal of dual seal system has failed, seal fluid will leak out of
the drain channels. Replace rear seal immediately (See section 7.12)
E. No RS485 signal.
1. Check the connector from sensor electronics to display unit.
2. Check the cable connections at pin 6 and 7 of Display Unit
connector board
3. Replace the Sensor Board
F. Raw output reading is
erratic
1. Take out KC/5 unit and check that the sensing element is clean. If
not clean - proceed as described in section 7.9
2. Check that area between sensing element and drive shaft does not
have a build-up of hard debris. Clean if necessary (See section 7.9 7.10).
3. Sensing element is spinning erratically (See section problem B).
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7.5 Removing the KC/5 sensor
sensor as per section 3.5.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Turn power switch OFF in the display unit.
Unplug the interconnect cable (See figure 7.1)
Close seal water line
Loosen the seal assembly locking ring
Jack the sensor to FULLY extracted position until jack stops
Close the gate valve
Open the drain valve in the mounting flange (verifying gate valve has good seal)
Disconnect the seal water hose connectors
Remove the locking bins and mounting bolts holding the sensor in the jack
Remove the sensor
Note! Position the sensor so that the sensing element does not rest on the locking ring while
pulling out the sensor unit. This may bend the sensing element and the moment shaft and cause
severe damage.
Gate Valve
Insertion
Jack 4
5
Sensor
9
6
Pipe
1
2
Drain 7
Valve
Locking
Ring 3
Mounting
Bolts 8
Figure 7-1. Removing the KC/5 sensor.
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7.6 On-line Zero check
KC/5 measurement zero reading may be checked while the KC/5 is operating the following way.
1. Go to “Factory settings”, Motor Controls” menu and press”→” Read the mNm value and record it
when sensor is operating normally.
2. Change the direction of rotation to CCW by pressing “↓”
3. Read the CCW mNm value and record it
4. Change the direction of rotation back to CW by pressing “↓”
5. Repeat the test by reading and recording the CW mNm value again.
6. Change the direction of rotation to CCW by pressing “↓”
7. Read the CCW mNm value again and record it.
8. The absolute value of the average CW torque readings and absolute value of the average CCW
torque readings should be closely on the same level indicating the zero point of torque measurement
has not drifted.
9. If absolute values differ more than 2 mNm, adjust Torque offset according to section 6.2.
10. Exiting the “Motor Controls” menu automatically returns the direction to CW
Note! When process had quick consistency changes, the zero check may give faulty results due to
rapidly changing torque measurement. In Medium consistency applications, changes in torque are
typically so big and fast, the on-line zero check does not give good results. In MC applications,
check the zero according to section 7.8. Checking the functionality of the KC/5.
7.7 On-line sensitivity check
KC/5 sensitivity may be checked with a Torque Brake while the KC/5 is operating. The Torque Brake is
available from KPM, part number A41040222.
1.
2.
3.
4.
5.
6.
7.
8.
Open the “Check torque” plug in the end of the sensor to expose the torque socket
Check the torque setup value from the torque brake (KPM brake 85 mNm).
Read the torque value “T” mNm -reading from ”maintenance” menu, “on-line signals
Connect the Torque Brake to the socket - this may be done without stopping the motor.
Hold the Torque Break firmly (not with excessive power) against the socket while avoiding contact
between shaft and case
Read the “T” mNm -reading from ”maintenance” menu, “on-line signals”
The T value mNm -reading should increase about the same than the brake set value from the nobrake level. If not, proceed as per section 7.7.
Reinstall the ”Check Torque” cap tightly
Figure 7-2. Sensitivity check with torque brake
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7.8 Checking the functionality of the KC/5 by removing the sensor from
the process
Remove the sensor from the process (see section 7.5)
1. Check the elastic protective shield and clean the front end of the probe
2. Place the KC/5 sensor unit into the horizontal position so the sensing element is free to rotate.
3. Connect seal water to the sensor
4. Connect the interconnect cable to the Sensor.
5. In the display unit, switch the power to the “On” position. The sensing element will rotate ClockWise –
CW – when looking from the Motor end of the KC/5.
6. The sensor is properly calibrated when “No-Torque T”-reading (the sensing element rotating in air) is
+/-2 mNm. T-value can be read from Maintenance/On-line Signals menu or from Calibration/Start
up/Torque Offset menu.
7. Clean the front part of the sensor and check to verify that, behind the sensing element, the elastic
shield is intact (see Section 7.10).
8. If the performance has not improved, then perform torque sensitivity calibration (see Section 7.9
below)
7.9 Torque sensitivity calibration
Torque calibration is performed by applying a measured torque force to the sensing element. The KC/5 is
factory calibrated using 0-85mNm. Low torque value, 0 mNm, is measured while the sensing element is
spinning in air.
1. Place sensor unit on the workbench with the display unit next to it.
2. Position the KC/5 so that the drive shaft is horizontal.
3. Connect seal water to the sensor
Note! When the KC/5 transmitter is operated in air, the mechanical seal will heat up if seal water is
not connected. This can damage the seal. To prevent this, make sure there is seal water in the
reservoir, or connect mill water to the seal water connections on the sensor.
4. Switch power ON in the display unit.
5. Select “torque setup” in maintenance menu and type in the high torque value to be used.
Press “ENTER” and place torque brake to the torque socket (See figure 7-2). Press “ENTER” to
initiate the calibration. After a while calibration raw value appears in display. “ENTER” accepts
the new number, “ESC” cancels.
6. Repeat above with low torque value (sensing element rotating freely in air).
7.10 Cleaning the sensing element
7.10.1. Cleaning debris wrapped around the sensing element using “Auto Reverse
Occasionally, debris catches on the sensing element – plastic, wire, string, etc. – and may even wrap
around the sensing element. This results in distortion of the measurement. Reversing the direction of the
rotation aids in removing the debris and foreign material.
1. Go to “Motor Controls” under “Factory Settings”. Select “Motor Direction” block, display
reads “CW” = clockwise. Select “CCW” = counter clockwise rotation direction.
2. Press ENTER and direction is reversed. Display returns to show RPM and T.
3. Allow the sensing element to run in reverse direction. Watch the “T” value decrease as debris is
released.
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4. Return to normal rotation “CW”. Check the “T” value – if it still shows the original value, repeat
reversed rotation a few times until “T” reading indicates the removal of the foreign particles.
7.10.2. Cleaning the sensing element manually
The sensing element must be free to rotate with reference to the drive shaft. This twisting action is the
essence of the torque measurement. If hardened debris or chemical additives build up on elastic shield or in
the region between the sensing element and the shield, it can cause the sensing element to lock-up on to
the end of the shaft. This can cause a loss of sensitivity, and in the worst case, cause the output to be
frozen at a constant reading. To clean, proceed as follows:
1. Remove sensor from the process line (See section 7.5).
2. Remove the sensing element by unscrewing the fixing screw (See figure 7-3).
3. Remove shield locking ring, if necessary for cleaning
4. Clean and remove any build-up on the sensing element, elastic shield, and the area in between
them.
5. Check the condition of elastic shield; if cut or broken replace with a new one (See section 7.10)
6. Reattach the sensing element to the moment shaft and tighten the fixing screw.
Figure 7-3. Sensor head and the shafts.
7.11 Replacing elastic shield, rod seal and needle roller bearing
If the protective elastic EPDM shield is damaged in any way, replace immediately. KC/5 elastic shield
replacement set contains the parts needed.
Content of Elastic Shield Replacement Set A41040302V1.1
Order Code Type
H41040158 Elastic Shield
2650016
Rod Seal
2750001
Needle Roller Bearing
2700015
O-ring 19.1x1.6 FPM
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7.11.1. Removing elastic shield
1. Remove the sensing element (See figure 7-3).
2. Open the screws in the shield locking ring. Remove the ring.
3. Open the set screws in the shield cover and pull off the shield cover. Elastic shield is removed with the
cover (see figure 7-4b).
Figure 7-4a. Sensor head
Figure 7-4b. Removing the elastic shield.
7.11.2. Removing rod seal and needle roller bearing
1. Pull out moment shaft bushing using two screw drivers (figure 7-5a)
2. Remove the seal washer to get access to the rod seal (figure 7-5b).
Figure 7-5a. Removing moment shaft bushing
Figure 7-5b. Removing seal washer
3. Remove moment shaft bushing (figure 7-5c) . Remove the needle roller bearing by tipping the sensor
head downwards and moving moment shaft radially (figure 7-5e). Check the condition of the needle
roller bearing (figure 7-5d). Replace the bearing if needed.
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Figure 7-5c. The rod seal location Figure 7-5d. Location of the needle roller bearing
Figure 7-5e. Removing the needle roller bearing
4. Clean the moment shaft of any dried material. Pay extra attention to area under the rod seal.
7.11.3. Installing elastic shield, rod seal and needle roller bearing
1.
2.
3.
4.
5.
Install the needle roller bearing. Use silicone oil as lubricant.
Place the new rod seal (Shield Replacement Kit) inside the moment shaft bushing.
Replace the moment shaft bushing O-ring with a new one from the replacement set
Reinstall the seal washer. Note that the bevelled side is facing the rod seal. (see figures.7-5b,c)
Slide the assembled bushing over the moment shaft, and slide it all the way down the shaft until it
stops on the drive shaft.
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Figure 7-6. Installation of the moment shaft bushing and the seal washer.
6. Place a new elastic shield into the shield cover. Pull the shield over the drive and moment shafts. To
reduce friction, wet the shaft surfaces with soapy water). Push -do not twist - the shield cover all the
way until the shield cover stops against the drive shaft.
7. Tighten the set screws on the shield cover (see figure 7-4a)
8. Place the shield locking ring on top of the elastic shield –do not fasten the screws yet.
9. Reattach sensing element to the moment shaft and tighten the fixing screw
10. Lift the shield locking ring until it rests against the sensing element and tighten the screws
7.12 Replacement of the mechanical seals
The KC/5 features tandem mechanical seals. The seal water is introduced between the front (process side)
and rear (motor side) seals. The front seal prevents pulp from getting inside the KC/5 probe housing. The
rear seal keeps seal water from getting to drive shaft bearings.
The seals are manufactured according to DIN 24960 standard and are available as stock items.
Front seal (process side)
“
Rear seal (motor side)
“
2650017
2650018
Order Code Type
Bellows Seal T502, SiC/EPDM
2650005
Stationary Seat C606/25, SiC/EPDM
Bellows Seal T502, SiC/FPM
2650007
Stationary Seat T6/25, SiC/FPM
Note: If Rear seal (motor side) has been in service more than three years, KPM recommends
replacement when the Front Seal needs replacement. Mechanical seal has an estimated lifetime of
five years.
Rear mechanical seal should be replaced if
1. When seal water/fluid is leaking out from the draining duct
2. When at the time of replacing the front mechanical seal, and the rear seal has been in service over 3
years
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3. When the rear seal has been in service for 5 years.
Figure 7-7. Location of the draining duct.
7.12.1. Removing front mechanical seal
1. Remove first the sensing element and the elastic shield (section 7.10.1 and figure 7-4)
2. Remove the front bellows seal by sliding it out with symmetrically placed screw drivers as shown in
figure 7-8a.
3. Unfasten the stationary seat by removing the locking ring (4 screws) (figure 7-8b)
4. Remove the front stationary seat with two screw drivers (figure 7-8c)
Figure 7-8a. Removing the bellows seal.
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Figure 7-8b. Removing the locking ring.
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Figure 7-8c. Removing the stationary seat with 2 screw drivers.
7.12.2. Removing rear mechanical seal
1. Anchor the sealing cover in a bench vice with lock ring. Break free the sleeve from the installation
assembly or use Sealing Cover Removal Tool H41040314 V1.0). Rotate the sensor head until the
head is completely open.
Figure 7-9. Opening the sealing cover
2.
3.
4.
5.
Open two set screws and remove Seal Locking Ring (see figure 7-10).
Remove the bellows seal by lifting it with symmetrically placed screw drivers.
Open the 4 screws of the seat adapter holding the rear stationary seat.
Remove the rear stationary seat from seat adapter by pushing forwards.
Figure 7-10. Removing the rear mechanical seal
6. Wipe the drive shaft clean and check that the draining duct is open.
7.12.3. Installation of front and rear mechanical seals
Wipe the drive shaft clean with soapy water before installing the rear stationary seal.
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Note: Use clean, soapy water to lubricate the seals and to reduce friction when installing seals.
NEVER use oil, grease or alcohol for this purpose.
1. Install seat adapter with 4 screws. Install the adapter so that seal water ducts are not blocked.
2. Push the stationary seat into seat adapter with polished side facing up. Use your hands to press the
stationary seal into place
3. Push the rear bellows seal on top of the stationary seat with polished face down
Figure 7-11. Rear seal compression adjustment.
4. Place the seal locking ring on top of the bellows seal and adjust the seal compression by pressing the
ring. Set installation length to 27 mm ±0.5 mm from the top of the seat adapter to the bottom of the
ring (see figure 7-11).
5. Lock the locking ring with two (2) set screws
6. Apply small amount of graphite grease (e.g. molykote) to the sealing cover threads.
7. Install the sealing cover. Anchor the sealing cover to a bench vice using the locking ring and brake
sleeve, or use the Sealing Cover Removal Tool, H41040314 V1.0, and fasten the sensor head (see
Figure 7-9).
8. Place the front stationary seat on the sealing sleeve. The polished side faces up. Use your hands to
press the mating ring into place (see figure 7-8c)
9. Install the locking ring and fasten the four (4) screws (see figure 7-8b)
Figure 7-12. Installing front seal.
10. Slide the front bellows seal over the drive shaft. Compress front seal to its smallest size.
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Figure 7-13. Installing shield cover.
11. Install the shield cover and the elastic shield (see fig 7-13). Push – do not twist – the shield cover until
the shield cover stops against the drive shaft.
12. Fasten 3 set screws.
13. Uncompress front sealing spring until it reaches the shield cover. Now installation length is correct.
14. Place the shield locking ring on top of the elastic shield. Leave screws loose
15. Reattach the sensing element to the moment shaft and tighten the fixing screw.
16. Lift the shield locking ring until it rests against the sensing element and fasten the locking ring screws
7.13 Electronics
KC/5 electronics contains the following replaceable boards/units:
1.
2.
3.
4.
5.
Part name
Optics Board
Sensor Board
Connection Board
AC/DC Power Supply
LC Display Board
Order Code
A41040062V1.0
A41040070V1.0
A410402202V1.0
3100003
A41080023V2.0
The KC/5 features helpful diagnostics to quickly locate faulty components. These easy-to-use diagnostics
are located in the “Maintenance / Check on-line signals” Section.
Check following first:
1.
Motor is running (RPM is as set).
2.
Friction is less than 1.5 Nm. (FRICTION)
3.
Motor voltage is 24 – 48 VDC (POWER)
If not, use wiring layout drawing (figure 7-14) to locate faulty component. To help pinpoint the problem,
check the following voltages:
AC/DC Power supply outlet voltage is 48±2VDC, measure from Connection Board.
Motor Supply voltage is 24 – 48 VDC, measure from Connection Board and from Sensor Board.
Sensor Supply Voltage is 12 VDC ± 1 VDC, measure from Connection Board and from Sensor Board.
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Jumper position:
JP1: Current output mode
Motor drive
Active (default)
Passive
Sensor Board
1
Optical disk
J1
9
Motor supply 24-48VDC
J7
_
+
Photo detector
8
1
2
9
7
1
6
3
Optics Board
4
5
6
7
8
1
2
9
6
3
5
Measurement signal
4
Quick
Connector
Commutation pulses
Interconnect Cable
AC/DC Power
supply
48 VDC
Mains Connector
85-264 AC in
Connection Board
Resettable fuse
Signal
Connn.
Board J1
Interconnect Cable
wire
Shield
1
shield
Current Loop +
2
white
Quick Connector
pin
Sensor Cable
wire
Sensor Board
J7
J1
1
white
8
Current loop -
3
brown
2
brown
9
Sensor Supply (+12V)
4
green
3
green
3
Sensor Supply GND
5
yellow
4
yellow
1
RS 485 A
6
grey
5
grey
6
RS 485 B
7
pink
6
pink
7
PWM Control (pulse)
8
blue
7
blue
5
Motor Supply +
9
black + gray/pink
8
black + gray/pink
2
Motor Supply GND
10
violet + red/blue
9
violet + red/blue
1
Figure 7-14. Wiring layout.
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7.14 Replacing Sensor Board
Refer to figure 7-15. To change the sensor board, proceed as follows:
1. Remove the KC/5 sensor from process line (See section 7.5).
2. Open the back of the enclosure by opening the 4 screws
3. Remove Plastic insulation cover
4. Disconnect the cable connectors (3 pcs) on the Sensor Board.
5. Unscrew the six screws which attach the measurement board to the end housing.
6. Uncouple the Sensor Cable wires on the board
7. Replace with a new board. Note the orientation of connectors (fig 7-15).
8. Reconnect the cables on the board.
Figure 7-15. Sensor electronics.
September 2006
W41040300 V3.01
Page 52 of 67
7.15 Replacing Optics Board
Refer to figure 7-16.
1. Open the small cover on side of the sensor housing, see fig 7-15.
2. Disconnect the optics cable connector on the optics board
3. Open 4 mounting screws and remove the board
4. Install a replacement board
5. Align the board so that the optics disks are in the middle of the alignment slot (see figure 7-16)
6. Connect the cable
Figure 7-16. Optics Board Alignment
7.16 Replacing Power Supply Unit
Disconnect AC power supply to Display Unit before starting the replacement work
Power supply unit provides 48 VDC operating voltage to the motor and 12 VDC for display and
measurement electronics.
1. Disconnect AC supply to Display Unit
2. Disconnect the cables between the connection board and the power supply unit and remove the
mounting screws (4 pcs) and the mounting bars (2 pcs), figure 7-17.
3. Mount a new unit and reconnect the cables
September 2006
W41040300 V3.01
Page 53 of 67
Figure 7-17. Display Unit.
7.17 Replacing Connection Board
Disconnect AC power supply to Display Unit before starting the replacement work
1. Disconnect AC supply from Display Unit
2. Disconnect 110/220 VAC mains power wires from the connection board
3. Remove the power supply unit (see section 7.15)
4. Disconnect all the cables, open the 4 mounting nuts of the board and the screw fastening the
regulator on the heat sink (fig 7-17)
5. Remove the board
6. Mount a replacement board
7. Install the screw fixing the regulator on the heat sink. Note the insulation pad between the heat
sink and the regulator, and the insulation bushing between the screw and the regulator (fig 7-18)
8. Check insulation between the regulator body and the display unit body with an ohmmeter (must be
over 1 MΩ)
9. Install 4 mounting nuts.
10.Re-install the removed power supply unit and connect the cables
September 2006
W41040300 V3.01
Page 54 of 67
Figure 7-18. Regulator isolation (bottom view of the connection board)
7.18 Replacing LC Display Board
1. Disconnect all the wires, open the 7 mounting nuts of the board and remove the board, see fig 717
2. Check the height of the LC Display board, the new version with backlight is thicker that the version
without backlight.
3. If you replace older type Board with new type, please install new spacers (7 pcs) delivered with the
new LC display board.
4. Mount the new board and connect the cables.
September 2006
W41040300 V3.01
Page 55 of 67
Appendix 1.1: Installation drawing - Meas. chamber PN10/16
3
4
This document must not be copied without our written
permission, and the contents thereof must not be imparted
to a third party or be used for any unauthorized purpose.
(c) Kajaani Process Measurements Ltd. 2002
2
1
Description
Vers.
Date
Prepd
D
C
PN10/16: a4
PN25: a7
A
B
82± 2.5
Tätä asiakirjaa ei saa ilman meidän lupaamme jäljentää.
Sitä ei myöskään saa esittää toiselle tai muutoin asiattomasti käyttää.
(c) Kajaanin Prosessimittaukset Oy. 2002
A
ø 215
A-A
Cut chamber to same radius with
existing prosess pipe.
A
September 2006
2
H41040324
1
H41040323
Item
Part No.
V1.1 Pipe
V1.0 Flange
Description
Vers.
Treatment
Material
KAJAANI PROCESS
MEASUREMENTS Ltd
Cross Sectional View
of Installation Chamber Assembly.
Notes
Tolerance
Title
Scale
KC/5 Meas.Chamber V1.1 PN 10/16, SS
Prepd
With cutting
W41040300 V3.01
1:4
12.09.06MLa
Drawing No.
E41040326 V1.1
Page 56 of 67
Appendix 2: BTG weld-in stud adapter and flange dimensions
September 2006
W41040300 V3.01
Page 57 of 67
Appendix 3: Assembly drawings and parts lists
Appendix 3.1.: Standard Meas. Chamber, PN10 Gate Valve
21
6
22
20
17
12
10
3
8
11
7
13
14
1
9
18
15
4
2
16
19
5
Item
Part No.
Description
Value Device Code
Qty
Unit
1
2000022
Vers.
Hex Screw
M8x100 DIN 931 A4
2
pcs
2
2000183
Screw, Socket Head Cap
M8x80 DIN 912 A4
6
pcs
3
2000097
Hex nut
M16 DIN 934 A4
4
pcs
4
2450004
Douple-nipple
R 1/4 Aisi316 DIN 2990
1
pcs
5
2450005
Ball valve, Reduced bore
R 1/4 Aisi 316 (onninen 2017k)
1
pcs
6
2600008
Knife Gate Valve PN10
Fabri C67S316EBU ANSI 125/150-3" Aisi 316
1
pcs
7
8
2700011
2700012
O-ring
O-ring
69.85x3.53 FPM
80x5 FPM
3
1
pcs
pcs
pcs
9
E41040326
V1.1
Meas. Chamber PN10/16
1
10
H31040129
V1.0
Mounting Flange, SS
1
pcs
11
H41040408
V1.0
Insertion Housing 67, SS
1
pcs
12
H41040128
V1.0
Flange Bolt
4
pcs
13
H41040131
V1.0
Lock Ring
1
pcs
14
H41040132
V1.0
Brake Sleeve
1
pcs
15
H41040134
V1.0
Flange Guide Ring
1
pcs
16
H41040135
V1.0
Housing Guide Ring
2
pcs
17
H41040140
V1.0
Guide Bol
4
pcs
18
H41040160
V1.0
2
pcs
19
2000158
20
H41040189
V1.0
Jack Bolt
21
E31040175
V1.2
Jack Assembly
22
2000115
September 2006
Flange Gasket
Locking Pin 3
M8x40 DIN 912 A4
LSA 4223 SS2331-06
W41040300 V3.01
1
pcs
4
pcs
1
pcs
4
pcs
Page 58 of 67
Appendix 3.2.: Standard Meas. Chamber, PN16 Gate Valve
21
6
22
20
17
12
10
3
8
11
7
13
14
1
9
18
15
4
2
19
16
5
Item
Part No.
Description
Value Device Code
Qty
1
2000022
Vers.
Hex Screw
M8x100 DIN 931 A4
2
Unit
pcs
2
2000183
M8x80 DIN 912 A4
6
pcs
3
2000097
Hex nut
M16 DIN 934 A4
4
pcs
4
2450004
Douple-nipple
R 1/4 Aisi316 DIN 2990
1
pcs
5
2450005
1
pcs
6
26000011
Knife Gate Valve PN16, hand operated
metal seat, wafer PN16 DN 80
1
pcs
7
8
2700011
2700012
O-ring
O-ring
69.85x3.53 FPM
80x5 FPM
3
1
pcs
pcs
pcs
9
E41040326
V1.1
Meas. Chamber PN10/16
1
10
H31040129
V1.0
Mounting Flange, SS
1
pcs
11
H41040408
V1.0
1
pcs
12
H41040128
V1.0
Flange Bolt
4
pcs
13
H41040131
V1.0
Lock Ring
1
pcs
14
H41040132
V1.0
Brake Sleeve
1
pcs
15
H41040134
V1.0
Flange Guide Ring
1
pcs
16
H41040135
V1.0
Housing Guide Ring
2
pcs
17
H41040140
V1.0
Guide Bol
4
pcs
18
H41040160
V1.0
Flange Gasket
2
pcs
19
2000158
1
pcs
pcs
M8x40 DIN 912 A4
20
H41040189
V1.0
Jack Bolt
4
21
E31040175
V1.2
Jack Assembly
1
pcs
22
2000115
4
pcs
September 2006
Locking Pin 3
LSA 4223 SS2331-06
W41040300 V3.01
Page 59 of 67
Appendix 3.3.: PN25 Installation Parts
2
1
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Part No.
20000158
2000175
2000176
2000177
2000178
2000179
2450004
2450005
2600017
2700011
2700012
E41040371
H31040372
H31040373
H41040132
H41040135
H41040374
H41040391
September 2006
Vers.
V1.0
V1.0
V1.0
V1.0
V1.0
V1.0
V1.0
Description
Hex nut
Hex Screw
Hex Screw
Hex Screw
Douple-nipple
Knife Gate Valve
O-ring
O-ring
Installation Cone PN25, DN100
Mounting Flange, PN25, DN100
Insertion Housing PN25
Brake Sleeve
Housing Guide Ring
Lock Ring PN25
Flange Gasket DN100 PN25
Value Device Code
M8x40 DIN 412 A4
M20 DIN 985 A4
M20x45 DIN 933 A4
M20x145 DIN 931 A4
M10x70 DIN 912 A4
M10x110 DIN 931 A4
R 1/4 Aisi316 DIN 2990
PN25, DN80, SMO 254, DN 100 Flange
69.85x3.53 FPM
80x5 FPM
W41040300 V3.01
Qty
1
6
4
6
6
2
1
1
1
3
1
1
1
1
1
2
1
2
Unit
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
Page 60 of 67
Appendix 3.4.: BTG Adapter, PN10 Gate Valve
22
6
23
18
10
13
21
3
11
15 14
7
1
X
12
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
X
9
Part No.
2000022
2000183
2000097
2450004
2450005
2600008
2700011
2700012
H31040233
H31040129
H41040408
H31040223
H41040128
H41040131
H41040132
H41040134
H41040135
H41040140
H41040160
2000158
H41040189
E31040175
2000115
2000123
September 2006
16
Vers.
V1.0
V1.0
V1.0
V1.0
V1.0
V1.0
V1.0
V1.0
V1.0
V1.0
V1.0
V1.0
V1.2
19
4
Description
Hex Screw
Hex nut
Double-nipple
Knife Gate Valve PN10
O-ring
O-ring
Installation Flange, BTG, SS
Mounting Flange, SS
Flange Gasket, BTG
Flange Bolt
Lock Ring
Brake Sleeve
Flange Guide Ring
Housing Guide Ring
Guide Bolt
Flange Gasket
Jack Bolt
Jack Assembly
Locking Pin 3
Screw, Hex cap
8
5
17
2
17
Value Device Code
Qty Unit
M8x100 DIN 931 A4
2
pcs
M8x80 DIN 912 A4
6
pcs
M16 DIN 934 A4
4
pcs
R 1/4 Aisi316 DIN 2990
1
pcs
1
pcs
Fabri C67S316EBU ANSI 125/150-3" Aisi 316 1
pcs
69.85x3.53 FPM
3
pcs
80x5 FPM
1
pcs
1
pcs
1
pcs
1
pcs
1
pcs
4
pcs
1
pcs
1
pcs
1
pcs
2
pcs
4
pcs
2
pcs
M8x40 DIN 912 A4
1
pcs
4 pcs
1 pcs
LSA 4223 SS2331-06
4 pcs
M8x25 DIN 933 A4
16 pcs
W41040300 V3.01
20
Notes
Not included in ass’y
Page 61 of 67
Appendix 3.5.: BTG Adapter, PN16 Gate Valve
22
6
23
18
10
13
21
3
11
15 14
7
1
X
12
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
X
9
Part No.
2000022
2000183
2000097
2450004
2450005
26000011
2700011
2700012
H31040233
H31040129
H41040408
H31040223
H41040128
H41040131
H41040132
H41040134
H41040135
H41040140
H41040160
2000158
H41040189
E31040175
2000115
2000123
16
Vers.
V1.0
V1.0
V1.0
V1.0
V1.0
V1.0
V1.0
V1.0
V1.0
V1.0
V1.0
V1.0
V1.2
September 2006
19
4
Description
Hex Screw
Hex nut
Double-nipple
Knife Gate Valve PN16, hand operated
O-ring
O-ring
Installation Flange, BTG, SS
Mounting Flange, SS
Flange Gasket, BTG
Flange Bolt
Lock Ring
Brake Sleeve
Flange Guide Ring
Housing Guide Ring
Guide Bolt
Flange Gasket
Jack Bolt
Jack Assembly
Locking Pin 3
Screw, Hex cap
8
17
5
2
20
17
Value Device Code
M8x100 DIN 931 A4
M8x80 DIN 912 A4
M16 DIN 934 A4
R 1/4 Aisi316 DIN 2990
metal seat, wafer PN16 DN 80
69.85x3.53 FPM
80x5 FPM
M8x40 DIN 912 A4
LSA 4223 SS2331-06
M8x25 DIN 933 A4
W41040300 V3.01
Qty
2
6
4
1
1
1
3
1
1
1
1
1
4
1
1
1
2
4
2
1
4
1
4
16
Unit
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
Notes
Not included in ass’y
Page 62 of 67
Appendix 3.6.: Sensor Front Assembly, PN16 SS
Sensor Front Assembly, PN16 SS
17
14
16
5
3
6
13
2
15
7
1
12
10
9
11
4
8
17
16
14
5
3
6
13
4
2
15
7
1
12
10
9
11
8
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
September 2006
Part No.
2000036
2000106
2000114
2000129
2650004
2650005
2650006
2650007
2700010
2700013
E31040153
H41040118
H41040119
H41040158
H41040182
H41040188
H41040244
Description
Screw,Slotted cheese head
Set Screw
Lock Ring
Screw, Slotted cheese head
Bellows Seal
Stationary Ring
Bellows Seal
Stationary Ring
O-ring
O-ring
Main Assembly
Seat Adapter
Sealing Cover
Protection Rubber
Snap Ring
Shield Cover
Shield Locking Ring
W41040300 V3.01
Page 63 of 67
Appendix 3.7.: Moment shaft and motor assembly
Moment shaft and motor assembly
19 8
9
13
2
5 11
1
10
18
4
16
17
12
14
3
15
6
C
7
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Part No.
2000093
2000109
2000111
2000112
2100004
2100005
2600007
2650008
2750001
2750002
2750005
2800001
E31040148
E41040145
E41040146
E41040152
H41040038
H41040108
H41040154
September 2006
Description
Lock Ring
Scerw, Socket Head Cap
Screw,Slotted cheese head
Scerw, Socket Head Cap
Wave Spring
Extension Spring 2.0xDu12x46
Cone Clamp
Radial Shaft Seal
Thrust Ball Bearing
Groove Ball Bearing
Rotor
Bearing Assembly
Drive Disk Assy
Moment Disk Assy
Body Assembly
Lock Cone
Moment Shaft
Seal Washer
W41040300 V3.01
Page 64 of 67
Appendix 4: KC/5 Spare parts Kit (Recommended Spare Parts)
KC/5 Spare parts
Description
Order Code
H41040158V1.0
2650016
2750001
2700015
2650017
2650005
2650018
2650007
A41040062V1.0
A41040070V1.0
A41040202V2.20
A41080023V2.0
3100003
2700011
2700012
A41040222V1.0
2000036
2000106
2000114
2000129
2700010
H41040118V1.0
H41040119V1.0
H41040182V1.0
H41040188V1.0
H41040244V1.0
H41040154
A41040175V1.0
E41040326V1.0
2600013
H41040327V1.0
2600008
2400001
E31040322V1.1
2600014
2600015
x
x
x
x
A41040302V1.1
A41040312V1.0
A41040313V1.0
x
September 2006
xx
xx
xx
xx
xx
xxx
xxx
xxx
xxx
xxx
xxx
xxx
xxx
xxx
xxx
xxx
xxx
xxx
xxx
xxx
xxx
Elastic shield EPDM
Rod Seal
O-ring 19.1*1.6 FPM
Front seal, Bellows Seal T502/GJ-1, SiC/EPDM
Front seal, Stationary Seat C606/25, SiC/EPDM
Rear seal, Bellows Seal T502/AJ-1, SiC/FPM
Rear seal, Stationary Seat T6/25, SiC/FPM
Optics Board
Sensor Board
Connection Board
LC Display Board
AC/DC Power Supply
O-ring, Seal sleeve, 69.85x3.53 FPM
O-ring, Mounting flange, 80x5 FPM
Torque brake
Screw, M4x10 DIN 84 A4
Set Screw M5x6 DIN 913 A4
Lock ring
Screw M3x8 DIN 84 A4
O-Ring 63x2, FPM
Seat Adapter
Sealing Cover
Snap Ring
Shield Cover
Shield Locking Ring
Seal Washer
Jack Assembly
KC/5 Meas. Chamber PN16 (precut for process pipe)
Blind Flange DN80 (PN25)
Blind Flange DN80 (PN10 / 16)
Knife gate valve AISI316 PN10
Knife gate valve AISI316 PN16
Meas. Chamber PN 10 / 16, SS, Not cutted
3"C67 Gate Valve EPDM gasket (P/N F153811)
3"C67 Gate Valve Acrylic Packing (P/N F137098)
KC/5 Elastic Shield Replacement Kit
KC/5 Mechanical Seal Replacement Kit
xxx KC/5 Complete Spare part kit
W41040300 V3.01
Page 65 of 67
Appendix 5: Model selection table
Type
KC5-S
Description
KC/-S Rotating Consistency Sensor
KC/5 Display Unit with Power Supply 85 - 264 VAC, 47 - 63 Hz, 150W
Sensor Wetted Parts Materials
S
T
SS316L
Titanium
Sensor Pressure class
16
25
PN16 (232 psi), Standard PN16 Sensor
PN25 (362 psi) PN25 Sensor, (mechanical seal rating PN25)
Process connection
KPM Measument Chamber V1.1 SS316L, PN10 / 16 (150 / 232 psi)
KPM Measument Chamber V1.1 SS316L, PN25 (362 psi) or Flange Mounted
KPM Measument Chamber V1.1 Titanium Gr2, PN10 / 16 (150 / 232 psi)
KPM Measument Chamber V1.1 Titanium Gr2, PN25 (362 psi) or Flange Mounted
KPM Measument Chamber V1.1 SAF2205, PN10 / 16 (150 /232 psi)
KPM Measument Chamber V1.1 SAF2205, PN25 (362 psi) or Flange Mounted
KPM Measument Chamber V1.1 SMO254, PN10 / 16 (150 /232 psi)
KPM Measument Chamber V1.1 SMO254, PN25 (362 psi) or Flange Mounted
Adapter for BTG MEK SS316L, PN10 / 16 (150 / 232 psi)
Adapter for BTG MEK SS316L, PN25 (362 psi), includes insertion assy
Adapter for BTG MEK Titanium, PN10 / 16 (150 / 232 psi)
K1
K2
K3
K4
K5
K6
K7
K8
B1
B2
B3
Gate Valve or Flange Mounted
G1
G2
G3
G4
G5
G6
G7
T1
T2
Gate Valve SS316L PN10 (150 psi)
Gate Valve 254SMO PN10 (150 psi)
Gate Valve SAF2205 PN16 (232 psi)
Gate Valve Titanium PN10 (150 psi) NOTE 1
Gate Valve Titanium PN16 (2320 psi) NOTE 1
Insertion Housing Assy (Seal sleeve + Locking ring)
S1
S2
S3
T1
S4
S5
S6
Insertion Housing 67 PN16, SS316L
Insertion Housing 67 PN16, 254SMO
Insertion Housing 67 PN16, SAF2205
Insertion Housing 67 PN16, Titanium Gr2
Insertion Housing PN25, SS316L
Insertion Housing PN25, 254SMO
Insertion Housing PN25, SAF2205
Installation Jack Assembly
J1
J2
J0
Jack Assembly
Jack Assembly PN25
No Installation Jack (Flange mounted)
Seal Water System
W
I
Low pressure seal water circulation (provided by customer)
Integrated seal water tank
Process pH-range
E
V
EPDM Elastic shield and front mechanical seal (pH-range 5-14)
Viton Elastic shield and front mechanical seal (pH-range 1-7)
Interconnect Cable
1
2
3
Interconnect cable 10m
Installation Position
H
V
Horizontal
Vertical
Process Pipe Diameter for pre-cutting the chamber
0 No pre-cutting or no measurement chamber
xxx Type in pipe size in inches or mm
September 2006
W41040300 V3.01
Page 66 of 67
Appendix 6: Technical specifications
SENSOR TYPE
Rotating Consistency Transmitter
OUTPUT SIGNAL
Analog output 4 - 20 mA + HART®, FDT/DTM, Foundation Fieldbus and
Profibus PA optional
BINARY INPUTS
24 VDC (supplied from DCS), three for built-in calibration curves, one for
process stop, one for sample button
BINARY OUTPUT
Alarm output; 24 VDC, 2A; Opening or closing dry contact
POWER REQUIREMENTS
Single phase, 84-264 VAC, 47-63 Hz, 2.5 Amp. 10 AT fuse required.
POWER CONSUMPTION
Max. 150 W
MOTOR
150 W integrated Direct Drive Servo Motor
MEASURING RANGE
1.5 % to 16 % consistency, full range with same sensing element
SENSITIVITY
Better than 0.003 % Cs
PRESSURE RATING
Sensor PN25 (232 psi)
Gate Valve PN10 (150 psi), PN16 (232 psi) or PN25 (362 psi).
PROCESS TEMPERATURE
0 - 120 °C (32 - 248 °F)
AMBIENT TEMPERATURE
Sensor 0 - 60 °C (32 - 140 °F), Display unit 0 - 50 °C (32 - 122 °F)
FLOW VELOCITY
0 - 5 m/s (0 - 16.4 feet/s)
SEAL COOLING
Seal water, R1/8” internal thread (compatible with NPT R1/8”). Optional Selfcontained seal fluid system.
HOUSING
Sensor IP66 (better than NEMA 4X), Display IP65 (NEMA 4X) enclosure.
CABLING
10 m (30’) interconnect cable from Sensor to Display Unit, 20m and 30m optional
GATE VALVE
DN80 (3") opening 316L standard, Duplex, SMO and Titanium available.
PROCESS CONNECTION
Measurement Chamber fits pipe diameters of 150 mm (6") and larger,
AISI 316L standard, Duplex, SMO and Titanium optional.
Adapter available for other manufacturer’s measuring vessels.
All required hardware included with the transmitter.
SENSOR MATERIAL
Wetted parts AISI 316L or Titanium.
DIMENSIONS (L*H*W)
AND WEIGHTS
Sensor unit: 520 x 140 x 180 mm (20.5“ x 5.5“ x 7“), 14.8 kg (32 lbs)
Installation assembly: 430 x 560 x 200 mm (17 x 22 x 8”), 19 kg (42 lbs)
Display Unit: 200 x 300 x 150 mm (7.9 x 11.8 x 5.9“), 6 kg (13 lbs)
September 2006
W41040300 V3.01
Page 67 of 67

INSTRUCTION MANUAL KC/5-S Rotating Consistency Transmitter

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